Hydroscand H24ap User manual

USER MANUAL

Edition I - 2013-02-20

Serial number: _________________

H24AP

H24HP

CONTENTS

1. INTRODUCTION........................................ 3

2. SAFETY RULES...................................... 3-4

3. EQUIPMENT...........................................4-7

3.1 WARRANTY....................................... 5

3.2 IMPORTANT...................................... 5

3.3 IDENTIFICATION .............................6-7

4. START - UP ......................................... 8-12

4.1 MACHINE PLACEMENT......................... 8

4.2 SELECTING DIE SET............................ 8

4.3 SETTING CRIMPING MEASUREMENTS .. 8-9

4.4 CHANGING DIE SET ........................ 9-10

4.5 CHANGING DIE SET WITH THE

QC- TOOL .......................................11

4.6 CRIMPING.......................................12

5. MAINTENANCE................................... 12-13

5.1 LUBRICATION ..................................12

5.2 CHANGING THE OIL...........................13

5.3 CHANGING THE BATTERY....................13

5.4 CALIBRATION ..................................13

6. TROUBLE SHOOTING ................................14

7. TECHNICAL DATA.....................................15

8. TECHNICAL DRAWS..................................16

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H24AP/HP USER MANUAL EDITION I 2013-02-20

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H24AP/HP USER MANUAL EDITION I 2013-02-20

1. Introduction

Do not unpack or operate the crimping machine until you have thoroughly read this

manual.

All who operate the crimping machine must read this manual.

This manual provides necessary information for safe use of this machine.

This manual is the result of continual development, testing and technical evaluations that

are registered and veried by Hydroscand Machine AB according to 2006/42/EC.

This information is intended only for specialized operators who can operate the machine

without risk to themselves, other persons, property, the machine, or the environment. The

operator should have fundamental knowledge in trouble-shooting methods, perform mach-

ine inspections and simple maintenance according to the information provided in this ma-

nual and according to local legislation for protection of health and safety.

This manual does not explain disassembly or comprehensive maintenance in detail. These

may only be performed by an authorized service technician.

It is necessary to store the manual and keep it in good condition for future use. Contact

your closest authorized supplier for a replacement manual or additional information if ne-

cessary.

This manual should be preserved and stored for the length of the machine’s lifetime or at

least ten (10) years in a well-known, easily accessible location together with other machine

documentation.

Hydroscand Machine AB is not liable for injury/damage to persons/machine or property as

a result of improper use, having made prohibited modications to the machine or misinter-

preting this manual’s safety instructions.

2. Safety rules

Always ensure that the minimum standards for safety, installation and operation are complied with

before operating the machine. Observe the surrounding environmental conditions such as temperature,

humidity, lighting, vibrations, dust and other conditions at the machine operation site. Never remove

the machine’s information or warning plates. Ensure that they remain clearly readable. Contact an aut-

horized service workshop for replacement plates if they become unreadable.

The use of any spare parts that deviate from this manual’s specications, any other changes/manipula-

tions (however insignicant) made to your machine releases Hydroscand Machine AB from any liability

for consequences that arise due to the machine’s performance, level of safety for nearby persons and/

or personal property.

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H24AP/HP USER MANUAL EDITION I 2013-02-20

Disassembling or side-stepping safety devices or rules is extremely hazardous and

absolutely prohibited. Refusal to follow these requirements puts others at severe risk

of injury!

Always dispose of operation waste according to current local laws and regulations.

Note!

All maintenance not described in this manual must be performed by an authorized service

technician.

3. Equipment

The machine is designed for smaller hose-crimping series and not for large-scale produc-

tion.

The machine consists of a chassis, crimping head and pump unit.

The machine is delivered ready to use, packed in a wooden box on a pallet marked with

serial number, order number, weight and volume. Compare your order with the delivered

product to ensure that everything is correct.

Remove all restraining clamps in the storage box, open the clip in the bottom and remove

the packing material.

Thread a lifting strap through the crimping head to lift the machine to the desired location.

H24AP/HP is a portable crimping machine powered by compressed air and designed for

service vehicles in the  eld or in a workshop. The machine is designed for smaller hose-

crimping series and not for large-scale production.

Metal clips, 10pcs

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H24AP/HP USER MANUAL EDITION I 2013-02-20

Note!

Always dispose of operation waste according to current, local laws and regulations.

The machine is delivered with:

• Lubrication tube

• Die change tool

• Certi cation of compliance according to CE requirements

• Manual

3.1 Warranty

The warranty lasts one (1) year from purchase and only under the strict condition that the manual

instructions have been followed. The warranty covers faulty material/parts and  awed workmanship,

replacing faulty parts cost.

The warranty does not cover improper use or normal wear. Travel costs, time for repair and shipping

costs are not covered by the warranty. Repairs under the warranty are to be made only by Hydroscand

Machine AB or an authorized service technician approved by Hydroscand Machine AB. Lost income or

extra costs that may arise for any reason are not covered by the warranty.

Note!

Ensure that the machine is undamaged and that all of the described items are present upon arrival or

shortly after. Hydroscand Machine is not liable for incorrect or missing parts that are not reported

within eight (8) days after delivery.

3.2 Important

These machines are designed and manufactured for crimping hydraulic hose in dimensionerna 3/16”-1

½”. Any other use of this machine is considered improper and Hydroscand Machine AB is not liable for

injury or damage to persons, property or the machine. The machine shall only be used for crimping

hydraulic hose according to speci cation. Hydroscand Machine AB’s instructions for operating

conditions and limitations for use/operation as well as health and safety regulations must be

complied with.

Warning !

Pinch point!

Keep hands and all other body parts away

from the red-indicated area while crimping.

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H24AP/HP USER MANUAL EDITION I 2013-02-20

3.3 Identication

The machine can be identied by the CE-label with the following information located on

its backside:

• Manufacturer

• Serial number

• Manufactured year

• Weight

• Voltage

• Pressure

• Force

Always provide the following information and technical explanation of the machine’s

problem when contacting the authorized service workshop:

• Model

• Serial number

• The manual’s version and date

Note!

It is absolutely prohibited to remove or damage the identication plates. Contact an authori-

zed service workshop for new plates if they become damaged and unreadable.

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H24AP/HP USER MANUAL EDITION I 2013-02-20

H24HP/H24AP

1. Pump handle

2. Carrying handle

3. Indicator lamp

4. Test button

5. Adjustment dial

6. On/off valve

7. Battery compartment

8. Tank lid

9. Dies

10. Crimping head

1. Pump regulator on/off

2. Carrying handle

3. Indicator lamp

4. Test button

5. Adjustment dial

6. Compressed air connection

7. Battery compartment

8. Dies

9. Crimping head

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H24AP/HP USER MANUAL EDITION I 2013-02-20

4. Start-up

4.1 Machine placement

Place the machine on a stable and at surface. Set the adjustable machine feet so that they cannot be

over-turned or fall from the surface. Connect to compressed air source, max 6 bar.

4.2 Selecting dies

Determine the crimping dimensions for the current operation and select the die set with the correct

interval that corresponds to the crimping measurement.

For example: A crimping measurement of 17mm, requires the die set size nr 16 (since it covers the 16-

19mm interval).

A die table on the machine indicates the crimping measurement interval for each die set. Crimping any

measurements outside the table crimping measurement interval is not recommended.

Always select the die set within the correct interval to achieve the best crimping results. Every die is

marked with the smallest crimping measurement in the interval.

Note!

Crimping any measurements outside the table crimping measurement interval is not recommended.

Using dies that are too small risk the ferrule becoming oval.

4.3 Setting crimping measurements

Turn the adjustment dial so that the zero (0) on the dial is lined-up with the zero (0) in the window. If

zero (0) is set, the machine will crimp the smallest diameter provided in the interval. Every revolution

of the dial increases the value in the window with one unit. One revolution clock-wise corresponds to

0.1mm on the crimping measurement. The measurement shall be added to the least-specied diameter

in the interval. Chart for die set sizing listed below.

For example: Crimping 16 mm hose requires die nr 16 with the adjustment dial set to zero (0) and lined

up with zero (0) in the window. Crimping 21,2mm hose requires die nr 19 with the adjustment dial

turned (two clock-wise rotations) at 2. Selecting 20 on the dial should line up with 2 in the window.

Make sure to lock the measurement dial when the desired crimping measurement is set. See table below:

Locking mechanism to lock

the set crimping measurement

The measured crimping diameter can sometimes differ

slightly from the set (requested) crimping diameter

because of expansion of the ferrule on the coupling.

Compensate this by readjusting the setting dial.

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H24AP/HP USER MANUAL EDITION I 2013-02-20

Die Set Crimping area

20-10

20-12

20-14

20-16

20-19

20-23

20-27

20-31

20-36

20-41

20-47

20-54

10-12 mm

12-14 mm

14-16 mm

16-19 mm

19-23 mm

23-27 mm

27-31 mm

31-36 mm

36-41 mm

41-47 mm

47-54 mm

54-61 mm

H24 DIES

4.4 Changing individual die segments

Place the machine on a stable and at surface. Adjust the machine’s feet so that they cannot

be over-turned or fall from the surface. If the optional die stand is used, the machine must be

bolted to the Die stand and the stand bolted to the oor.

1. Retract the dies completely by pressing the return button twice.

2. Remove a die segment by using the included tool and pull the die set pin

until the die releases.

3. Make sure the 8-segment die set is clean, undamaged and that all die seg -

ments are the same size with the die size markings facing towards you.

Insert the dies from the front. Mount the die segment by pulling the die set pin

with the QC-tool, insert the die set pin in the hole in the master die and release

the locking pin with the QC-tool.

4. Ensure that all die segments are correctly inserted in the machine.

20-10 10 11 12 10 10 10 10 10

0 turn 1 turn 2 turns 3 turns 4 turns 5 turns 6 turns 7 turns

20-12 12 13 14 12 12 12 12 12

20-14 14 15 16 14 14 14 14 14

20-16 16 17 18 19 16 16 16 16

20-19 19 20 21 22 23 19 19 19

20-23 23 24 25 26 27 23 23 23

20-27 27 28 29 30 31 27 27 27

20-31 31 32 33 34 35 36

36 37 38 39 40 4120-36

41 42 43 44 45 46 4720-41

47 48 49 50 51 52 53 5420-47

54 55 56 57 58 59 60 6120-54

USE NEXT SIZE!

H24 DIE SET SIZING CHART

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H24AP/HP USER MANUAL EDITION I 2013-02-20

1. Locking pin

2. Die

3. QC - tool

1 Die size marking

2. Die set pin

3. QC - tool

4. Hole for QC Tool

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H24AP/HP USER MANUAL EDITION I 2013-02-20

4.5 Changing die sets with the QC-tool

The QC-tool allows you to change entire die sets in just one step.

1. Fully contract the dies together to zero (0). Insert the QC-tool in the holes for the

QC change tool in the contracted dies and then completely retract (return) the

dies. Insert the die set in its storage compartment (QC-rack or QC-stand) and turn

the tool counter-clockwise until it stops. Remove the tool.

2. Completely retract the die set.

3. Insert the QC-tool in the desired storage compartment and turn clock-wise until it

stops. Pull out the die set and mount them in the machine.

4. Contract the dies together until they click in place.

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H24AP/HP USER MANUAL EDITION I 2013-02-20

4.6 Crimping

1. Once the desired die set is mounted, place the hose application between the dies.

2. H24HP: Turn the on/off valve dial clockwise until the dial stops. Pump the hand pump

until the indicator lamp lights.

3. H24AP: Turn the on/off valve dial counter-clockwise to contract the dials and release

the hose application.

4. Check the crimped hose and make adjustments if necessary.

5. Maintenance

5.1 Lubrication

The machine should be cleaned and lubricated every eight (8) operation hours. Retract the dies to

lubricate. Use a small brush to lubricate the cone-like surfaces in the cylinder. It is better to

lubricate sparingly and more often than seldom and excessively. Without lubrication, the machine

looses power and can damage the gliding surfaces.

Use only the lubrication recommended by Hydroscand Machine AB: Optimol viscogen 4

WARNING!

Pinch point! Keep hands

clear of the dies when

crimping!

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H24AP/HP USER MANUAL EDITION I 2013-02-20

5.2 Changing the oil

The oil should be changed once per year. Retract the dies.

H24AP: Fill oil to the line on the oil-level glass on the front of the pump.

H24HP: Fill to the line on the oil-stick

Use only the oil recommended by Hydroscand Machine AB: ISO VG32

H24HP: Oil change, the following must be done:

1. Open release crane

2. Pump slowly many times

3. Close the release crane

4. Air the hose and cylinder by pumping slowly to oil without air bubbles coming at the cylinder.

5. The hand pump is now ready to use.

5.3 Changing the battery

When the light indicator lamp becomes weaker then it is time to change the battery. Open the lid and

replace the battery.

Battery type: 9V

5.4 Calibration

If the actual crimping measurement differs too much from the set crimping measurements then cali-

brate the machine.

1. Insert a pipe/hose in the machine and crimp.

2. Measure the crimped application thoroughly.

3. Release the setting dial.

4. Turn the setting dial to the crimping measurement previously completed.

5. Return the setting dial.

6. Check. Repeat the procedure if the actual crimping measurement differs from the set crim

ping measurement.

Locking mechanism to lock

the set crimping measurement

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H24AP/HP USER MANUAL EDITION I 2013-02-20

6. Trouble shooting

Problem

Inconsistent crimping

measurements:

Low crimping force:

1. Too-little lubricant

2. Setting dial lost its position

1. Too-little lubrication

2. Low oil level

3. On/off valve not tightened

enough

4. Leakage

5. Poor oil quality

6. Pump leakage

Lubricate

Calibrate

Lubricate

Fill oil

Tighten

Tighten pipes

Change oil

Replace seals

Reason Solution

DIMENSIONS H24HP:

Widht/ Depth/ Height ..........................520x400x370 mm

Weight ............................................................... 75 kg

DESIGNATION PART NUMBER:

H24HP........................................................ 9028-00-73

TECHNICAL DATA H24HP:

Crimping range in mm .................................. 10 - 61 mm

Crimping range in inch ..................................0,39 - 2,40

Crimping force in metric tons................................... 140

Crimping force in kN ............................................. 1400

Maximum hose size in inch .................................... 1 ½”

Die Set .................................................................H24

Maximum travel of dies in mm..............................25 mm

Master die Diam. /Length in mm..........................84 / 80

Master die Diam. /Length in inches.................3,31 / 3,15

Machine control ................................................ Manual

Motor size in kW 1 phase / 3 phase................................

.......................................................275 Bar Handpump

Motor size in HP 1 phase / 3 phase ................................

.......................................................275 Bar Handpump

Colour................................................... Black / Orange

DIMENSIONS H24AP:

Widht/ Depth/ Height ..........................520x400x370 mm

Weight ............................................................... 69 kg

DESIGNATION PART NUMBER:

H24AP........................................................ 9028-00-74

TECHNICAL DATA H24AP: